Sign up to receive free email alerts when patent applications with chosen keywords are publishedSIGN UP

Abstract:

There is disclosed a noise reduction member. Preferably, the noise
reduction member is employed for sealing or baffling within a pillar or
other structure of an automotive vehicle, although not required.

Claims:

1. A noise reduction system, comprising: a structure of an automotive
vehicle; a noise reduction member located within the cavity of the
structure, the noise reduction member including: i. a carrier member
having a top wall, a bottom wall, and a third wall, the top wall and
bottom wall each including a securement flange extending therefrom; ii. a
mass of expandable material located adjacent the top wall; and iii. an
attachment integrally formed with the carrier member of a polymeric
material and attached to the carrier member, the expandable material or
both and locating the noise reduction member relative to the structure;
wherein upon expansion of the expandable material: i. the top wall,
shields the expandable material from forming a foam material in a space
adjacent the structure; ii. the mass of expandable material expands to
form a foam that occupies a volume that is at least 500% of the volume
occupied by the original unexpanded mass of expandable material; iii. the
third wall includes an opening through which the foam flows during
expansion so that the foam contacts a wall of the structure to which the
attachment is attached; and iv. the securement flanges extend into the
structure to control the expansion direction of the foam.

2. A system as in claim 1 wherein the structure includes an opening and
the expandable material is prohibited from forming a foam material
covering the opening due to the space adjacent the structure.

3. A system as in claim 1 wherein the mass of expandable material expands
to form a foam that occupies a volume that is at least 2000% of the
volume occupied by the original unexpanded mass of expandable material.

4. A system as in claim 1 wherein, upon expansion, the expandable
material substantially entirely fills a section of a cavity of the
structure in which the member has been placed and forms a foam that spans
across a cross-section of the cavity for inhibiting the passage of mass
and sound through the cavity.

5. (canceled)

6. A system as in claim 1 wherein the second wall is located adjacent an
opening of the structure for, upon expansion of the mass of expandable
material, shielding the expandable material from forming a foam material
that covers the opening

7. (canceled)

8. A system as in claim 1 wherein the top wall is substantially parallel
to the bottom wall.

9. A system as in claim 1 wherein the top wall, bottom wall and
attachment of the carrier member are integrally formed of a polymeric
material.

10. A system as in claim 1 wherein the volume of the mass of expandable
material is greater than about 1 cm3 but less than about 2 cm.sup.3.

11. A system as in claim 1 wherein the expandable material is a heat
activated thermosetting material that foams, expands and cure upon
exposure to temperature in an e-coat or bake oven.

12-20. (canceled)

21. A noise reduction system, comprising: a structure of an automotive
vehicle; a noise reduction member located within the cavity of the
structure, the noise reduction member including: i. a carrier member
having a top wall, a bottom wall, and a third wall, the top wall and
bottom wall each including a securement flange extending therefrom; ii. a
mass of expandable material located adjacent the top wall, the material
being located in direct planar contact with each securement flange; and
iii. an attachment integrally formed with the carrier member of a
polymeric material and attached to the carrier member, the expandable
material or both and locating the noise reduction member relative to the
structure; wherein upon expansion of the expandable material: i. the top
wall, shields the expandable material from forming a foam material in a
space adjacent the structure; and the mass of expandable material expands
to form a foam that occupies a volume that is at least 500% of the volume
occupied by the original unexpanded mass of expandable material; iii. the
third wall includes an opening through which the foam flows during
expansion so that the foam contacts a wall of the structure to which the
attachment is attached; and iv. the securement flanges extend into the
structure in a direction that is substantially parallel to the opening in
the third wall to control the expansion direction of the foam.

22. A system as in claim 21 wherein the volume of the mass of expandable
material is greater than about 1.5 cm3 but less than about 4
cm.sup.3.

23. A system as in claim 21 wherein the top wall is substantially
parallel to the bottom wall and the top and bottom wall are substantially
perpendicular to the third wall.

24. A system as in claim 21 wherein the mass of expandable material
expands to form a foam that occupies a volume that is at least 2000% of
the volume occupied by the original unexpanded mass of expandable
material.

25. A system as in claim 21 wherein, upon expansion, the expandable
material substantially entirely fills a section of a cavity of the
structure in which the member has been placed and forms a foam that spans
across a cross-section of the cavity for inhibiting the passage of mass
and sound through the cavity.

26. A system as in claim 21 wherein the mass of expandable material is
located substantially entirely in the cavity of the carrier member,
extending along an elongated axis and wherein: i) any diameter of the
mass of expandable material taken perpendicular to the elongated axis are
shorter the dimension; ii) the mass of expandable material is
substantially entirely located between the top wall and the bottom wall;
iii) the mass of expandable material is generally shaped as a polyhedron
having sides that are square, rectangular or both; and iv) the mass of
expandable material is configured to volumetrically expand to a volume
that is at least 3000% of its original unexpanded volume.

27. A noise reduction member as in claim 21, wherein the flanges extend
into the cavity beyond the expandable material in its unexpanded state to
increase the size of the areas adjacent the carrier into which the foam
does not expand.

28. A noise reduction member as in claim 21, wherein the top wall, bottom
wall, third wall, securement flange and fastener of the carrier member
are integrally formed of a polymeric material.

29. A noise reduction system, comprising: i. a carrier member having: a.
a top wall and a bottom wall, the top wall and bottom wall
interconnecting with a side wall at top and bottom intersection points to
define a cavity; b. a securement flange extending from each of the top
wall and bottom wall into a vehicle structure; ii. a mass of expandable
material having a plurality of planar walls and an axis of elongation
disposed between the top wall and bottom wall and wherein the securement
flange extends beyond an edge of the expandable material prior to
expansion to create cavities adjacent the carrier and beyond any edge of
the carrier into which the foam does not expand so that the expandable
material expands along the axis of elongation and the carrier member
contacts the expandable material on exactly four walls of the expandable
material; iii. a fastener integrally molded with the carrier member
extending into and through an opening of the vehicle structure for
attaching the carrier member to the vehicle structure, wherein the
fastener is located in between the top and bottom intersection points;
wherein the top wall, bottom wall, side wall, securement flange and
fastener of the carrier member are integrally formed of a polymeric
material and wherein the top wall, bottom wall and securement flanges
assist the expandable material in forming cavities that provide space
both above and below the carrier member so that any openings in the
vehicle structure located in these cavities will not be covered by the
expandable material and will remain useful for allowing components to
extend into and through the openings such that the size of the cavities
formed by the top wall, the bottom wall and the expandable material
depends on the length of the top wall, bottom wall, and securement
flanges.

Description:

CLAIM OF PRIORITY

[0001] This application claims the benefit of the filing date of U.S.
Provisional Application Nos. 60/688,255 filed Jun. 7, 2005.

FIELD OF THE INVENTION

[0002] The present invention relates generally to a member for providing
noise reduction to an article of manufacture (e.g., an automotive
vehicle) through baffling, sound absorption, a combination thereof or the
like.

BACKGROUND OF THE INVENTION

[0003] For many years, industry (e.g., the transportation industry) has
been concerned with designing members for providing noise reduction
(e.g., baffling, sound absorption, combinations thereof or the like) to
articles of manufacture such as automotive vehicles. Typically, such
members include expandable materials, which may or may not be supported
by carrier members, and which, upon expansion, form seals, baffles, sound
absorption systems or the like in one or more cavities of an article of
manufacture.

[0004] Design of such members can involve multiple competing
characteristics. For example, it may be desirable for the members to be
relatively lightweight while still maintaining the ability to exhibit a
relatively high degree of noise reduction. Other desirable
characteristics for the members can include, without limitation, low
cost, ease of assembly, ease of manufacture compatibility with the
articles of manufacture to which the members are applied and other
factors. Thus, the present invention provides a noise reduction member
and system that exhibits at least one, but preferably multiple desirable
characteristics.

SUMMARY OF THE INVENTION

[0005] The present invention is directed to a noise reduction member. The
member typically includes a carrier member and an expandable material.
Preferably, the carrier member includes one or more walls for guiding the
expansion of the expandable material and will also typically include an
attachment for locating the noise reduction member at least temporarily
relative to a structure of an article of manufacture. The expandable
material is preferably a relatively high expansion material.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] The features and inventive aspects of the present invention will
become more apparent upon reading the following detailed description,
claims, and drawings, of which the following is a brief description:

[0007] FIG. 1 is a perspective view of an exemplary member in accordance
with an aspect of the present invention.

[0008] FIG. 2 is another perspective view of the exemplary member of FIG.
1.

[0009] FIG. 3 is a cut away side view of the exemplary member of FIGS. 2
and 3 applied to a structure of an automotive vehicle.

[0010] FIG. 4 is a cut away side view of the exemplary member and
structure of FIG. 3 after expansion of an expandable material of the
member. to form an exemplary system.

[0011] FIG. 5 is a magnified view of a portion of the exemplary system of
FIG. 4.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0012] The present invention is predicated upon the provision of a member
suitable for providing noise reduction to one or more structures of an
article of manufacture typically by providing baffling, sound absorption,
sound deflection, a combination thereof or the like to the structures.
Together, the one or more structures and the member form a system or
assembly that is generally desirable for the article of manufacture
because of the functional attributes (e.g., noise reduction, baffling,
sealing, strength, reinforcement combinations thereof or the like)
provided by the member. It is additionally contemplated that the member
may be able to provide structural reinforcement to the structure of an
article of manufacture.

[0013] It is contemplated that the member may be employed in conjunction
with a variety of structures of various articles of manufacture such as
boats, trains, buildings, appliances, homes, furniture or the like. It
has been found, however, that the member is particularly suitable for
application to structures or assemblies of transportation vehicles such
as automotive vehicles. Generally, it is contemplated that the member may
be applied to various structures such as components of a body, a frame,
an engine, a hood, a trunk, a bumper, a pillar combinations thereof or
the like of an automotive vehicle.

[0014] The noise reduction member typically includes one or more of the
following:

[0015] i) a carrier member that typically includes at least one, but more
preferably two, three or more walls, one of which typically includes a
through-hole extending therethrough, although not required;

[0016] ii) an expandable member connected to the carrier member wherein
the expandable material is typically located adjacent (e.g., between) a
first and/or a second wall of the carrier member, although again, not
required; and

[0017] iii) an attachment (e.g., a fastener) connected to the carrier
member the expandable material or both.

[0018] Upon expansion, the expandable material can, if desired, be
configured to substantially entirely fill a section of a cavity in which
the member has been placed. In such an embodiment, the expandable
material typically expands to form a foam that spans across a
cross-section of the cavity for inhibiting or prohibiting the passage of
mass (e.g., dust and debris) and or sound (e.g., noise) through the
cavity.

[0019] The member of the present invention is typically or primarily
employed for sound (e.g., noise) reduction within an article of
manufacture (e.g., used as a baffle within a cavity of an automotive
vehicle). It is contemplated, however, that the member may be
additionally or alternatively used as a separator, a reinforcement, a
hole plug, a blocking member, a combination thereof or the like.

[0020] The member of the present invention is typically comprised of a
carrier member and at least one mass of an expandable material connected
to and preferably at least partially supported by the carrier member. The
carrier member typically includes at least one, but preferably a
plurality of walls and the at least one or plurality of walls typically
define a cavity suitable for receipt of at least one mass of expandable
material.

[0021] Referring to FIGS. 1 and 2, there is illustrated an exemplary
member 10 according to the present invention. The member 10 includes a
carrier member 12 and a mass 14 of expandable material connected to the
carrier member 12. Generally, the carrier member 12 and the mass 14 of
expandable material may be shaped in a variety of configurations within
the scope of the present invention. Thus, the specific shapes and
configurations of the carrier member 12 and the mass 14 of expandable
material in the figures and description should not limit the present
invention, unless otherwise specifically stated.

[0022] The carrier member 12 is shown to have a first or top wall 20, a
second or bottom wall 22 and a third or side wall 24 interconnecting the
top and bottom walls 20, 22. The first wall 20 opposes the second wall 22
and, in the embodiment shown, the first wall 20 is substantially parallel
to the second wall 22. Moreover, the first wall 20, the second wall 22
and the side wall 24 are each substantially planar, although they may be
contoured if needed or desired.

[0023] Generally, the walls 20, 22, 24 or the carrier member 12 define a
cavity 30 suitable for receipt of the mass 14 of expandable material. In
the particular embodiment illustrated, the first wall 20 and the second
wall 22 (or the planes in which they are disposed) extend away, at skew
(e.g., perpendicular) angles 34, 36 relative to the side wall 24 (or the
plane in which it is disposed). In this configuration, the first wall 20,
the second wall 22 and the third wall 24 form a C-shape thereby defining
the internal cavity 30.

[0024] It should also be noted that an opening 40 is defined in the
carrier member 12 and particularly in the third wall 24 of the carrier
member 12. The particular opening 40 shown-is illustrated as a generally
rectangular through-hole that extends through the third wall 24 or the
carrier member 12.

[0025] Typically, although not necessarily required, the member of the
present invention will include one or more fasteners or attachments which
may be connected to the carrier member, the expandable material or both.
As such, the fastener or attachment may be formed, molded or shaped of
the same material of the carrier member and/or the expandable material
or, alternatively, may be a separate member that is attached or connected
to one or both of the expandable material and the carrier member. The
attachment may also be an attachment medium such as an adhesive or
magnetic medium.

[0026] It is also contemplated that any fastener of the present invention
may be formed in a variety of configurations. Examples include, without
limitation, arrowhead fasteners, clip, rivets, interlocking mechanisms,
combinations thereof or the like.

[0027] The illustrated member 12 includes a fastener 44 attached to and
integrally formed of the same material of the carrier member 12. The
fastener 44 is illustrated as a flange 46 that opposes a substantial
portion of the opening 40 in the side wall 24. The fastener 44 includes a
first generally rectangular portion 50 extending outwardly away. from the
carrier member 12, a second generally rectangular portion 52 cantilevered
and extending downwardly away from the first portion 50 and a third
generally rectangular portion 54 extending outwardly away from the second
portion at an angle.

[0028] The carrier member 12 can also include one or more securement
flanges 60. Such flanges 60 typically extend toward and/or into the
cavity 30 defined by the carrier member 12, although not required. The
exemplary illustrated carrier member 12 includes at least one flange 60
extending into and/or toward the cavity 30 from each of the top wall 20
and the bottom wall 22 of the carrier member 12. More particularly, both
the top wall 20 and bottom wall 22 include a pair of flanges 60 shown as
barbs extending into and/or toward the cavity 30 from adjacent opposite
edges of each of the top wall 20 and the bottom wall 22 of the carrier
member 12.

[0029] The carrier 12 including the walls 20, 22, 24 and the fastener or
attachment 44 may be integrally formed of a singular material or may be
separately formed of different materials. Materials for the carrier
member and its respective components may be formed of or include, without
limitation, metals, polymeric materials (e.g., nylon, polyamide,
polyester, polypropylene, polyethylene or others), which may be filled or
unfilled (e.g., filled with glass reinforcement fibers) or other
materials. As such, the carrier member, may be processed and/or formed
using metal forming techniques such as bending, extruding or the like and
may be processed and/or formed using polymer shaping techniques such as
molding (e.g., blow molding, injection molding compression molding or the
like). In one preferred embodiment the carrier is integrally formed of a
metal material such as aluminum, steel or the like and is stamped into
its desired shape (e.g., the shape shown is FIGS. 1-3).

[0030] As discussed, the mass of expandable material may be shaped in a
variety of different configurations and there may be multiple different
masses of expandable material. Preferably, at least one mass of
expandable material is located at least partially (e.g., at least 10% of
the volume of the mass) or substantially entirely (e.g., at least 70%,
80%, 90% or more) in the cavity of the carrier member, although not
required. It is also preferable for, at least one mass of expandable
material to be located at least partially (e.g., at least 10% of the
volume of the mass) or substantially entirely (e.g., at least 70%, 80%,
90% or more) between the first wall 20 and second wall 22 of the carrier
member 12, although not required.

[0031] The mass 14 of FIGS. 1-3 extends along an axis 64 of elongation and
has at least one dimension (D) extending substantially parallel to that
axis 64. That dimension (D) can be selected from length, height or other
dimension. In one embodiment, any and/or every diameter of the mass of
expandable material taken perpendicular to the elongated axis 64 are
shorter than the dimension (D). As used herein, diameter is meant to
include any line segment extending from one surface of the mass to
another surface of the mass.

[0032] It is contemplated that the mass of expandable material may be
formed into a variety of shapes and configurations. The walls of the mass
may be planar or contoured and the mass may be geometric or non-geometric
or a combination thereof. In the embodiment illustrated, the mass 14 of
expandable material is generally shaped as a polyhedron having sides that
are respectively square and rectangular.

[0033] The volume of the mass of expandable material may be relatively
large or relatively small prior to expansion thereof. As such, the size
or volume of the mass should not be limited unless otherwise specifically
stated. Generally, however, preferred embodiments of the invention have a
mass of expandable material with a volume that is greater than about 0.5
cm3, more typically greater than about 1.0 cm3, and even more
typically greater than about 1.5 cm3 and a volume that is less than
about 10 cm3, more typically less than about 4.0 cm3 and even
more typically less than about 2.0 cm3.

[0034] A variety of expandable materials may be used for the mass of
expandable material of the present invention. In one embodiment, the
material may be formed of a heat activated material and may flow, cure
(e.g., be thermosettable), foam or a combination thereof upon exposure to
heat. The expandable material may be generally dry to the touch and
substantially tack free or may be tacky and, in either situation, may be
shaped in any form or desired pattern, placement, or thickness, but is
preferably of substantially uniform thickness. Exemplary expandable
materials are L-7102 and L-7220 foam available through L&L Products, Inc.
of Romeo, Mich. Another exemplary expandable material is disclosed in
U.S. patent application titled "Expandable Material", Ser. No.
10/867,835, filed on Jun. 15, 2004 and incorporated herein by reference
for all purposes.

[0035] Though other heat-activated materials are possible, a preferred
heat activated material is an expandable polymer or plastic, and
preferably one that is foamable. Particularly preferred materials are
epoxy-based, acrylate-based or acetate-based foams, which may be
structural, sealing, sound damping, sound absorbing, sound attenuating or
a combination thereof. For example, and without limitation, the foam may
be an epoxy-based material, including an ethylene copolymer or terpolymer
that may possess an alpha-olefin. As a copolymer or terpolymer, the
polymer is composed of two or three different monomers, i.e., small
molecules with high chemical reactivity that are capable of linking up
with similar molecules.

[0036] A number of epoxy-based or otherwise based sealing, baffling or
acoustic foams are known in the art and may employed in the present
invention. A typical foam includes a polymeric base material, such as an
epoxy resin or ethylene-based polymer which, when compounded with
appropriate ingredients (typically a blowing and curing agent), expands
and cures in a reliable and predictable manner upon the application of
heat or the occurrence of a particular ambient condition. From a chemical
standpoint for a thermally-activated material, the structural foam is
usually initially processed as a flowable thermoplastic material before
curing. It will cross-link upon curing, which typically makes the
material incapable of further flow (e.g., thermoset).

[0037] One advantage of the preferred foam materials over prior art
materials is that the preferred materials can be processed in several
ways. The preferred materials can be processed by injection molding,
extrusion, compression molding or with a mini-applicator. This enables
the formation and creation of part designs that exceed the capability of
most prior art materials.

[0038] While preferred materials have been disclosed, other materials may
be used as well, particularly materials that are heat-activated or
otherwise activated by an ambient condition (e.g. moisture, pressure,
time, chemical reaction or the like) and cure in a predictable and
reliable manner under appropriate conditions for the selected
application. Of course, the material may also be formed of
non-activatable materials, non-expandable materials or otherwise. Thus,
upon activation, the material may soften, cure and expand; soften and
cure only; cure only; soften only; or may be non-activatable.

[0039] One example of an expandable material is the epoxy based resin
disclosed in U.S. Pat. No. 6,131,897, the teachings of which are
incorporated herein by reference. Some other possible materials include,
but are not limited to, polyolefin materials, copolymers and terpolymers
with at least one monomer type an alpha-olefin, phenol/formaldehyde
materials, phenoxy materials, and polyurethane materials with high glass
transition temperatures. See also, U.S. Pat. Nos. 5,766,719; 5,755,486;
5,575,526; and 5,932,680, (incorporated by reference). In general,
desired characteristics of the material can include adhesion durability
properties or the like, although such properties are not necessarily
required. Generally, it is desirable that the material does not generally
interfere with the materials systems employed by automobile manufacturers
or other manufactures.

[0040] Other exemplary expandable materials can include combinations of
two or more of the following: epoxy resin, polystyrene, styrene
butadiene-styrene (SBS) block copolymer, butadiene acrylo-nitrile rubber,
amorphous silica, glass microspheres, azodicarbonamide, urea,
dicyandiamide. Examples of such materials are sold under the tradename
SIKAELASTOMER, SIKAREINFORCER and SIKABAFFLE and are commercially
available from the Sika Corporation, Madison Heights, Mich.

[0041] In applications where the material is a heat activated, thermally
expanding and/or foaming material, an important consideration involved
with the selection and formulation of the material forming the foam is
the temperature at which a material reaction or expansion, and possibly
curing, will take place. Typically, certain expandable material
ingredients become reactive at higher processing temperatures, such as
those encountered in an automobile assembly plant, when the material is
processed and/or activated along with the automobile components at
elevated temperatures or at higher applied energy levels, e.g., during
paint or e-coat baking or curing steps. While temperatures encountered in
an automobile assembly operation may be in the range of about
148.89° C. to 204.44° C. (about 300° F. to
400° F.), body and paint shop applications are commonly about
93.33° C. (about 200° F.) or slightly higher. If needed,
various different blowing agents or blowing agent activators can be
incorporated into the composition to cause expansion at different
temperatures outside the above ranges. Generally, suitable expandable
materials have a volumetric range of expansion ranging from approximately
0 to over 1000 percent. For example a mass of expandable material may
expand to form a foam that occupies a volume that is (e.g., is at least
partially located within) at least 150%, 200%, 500%, 1000%, 1500%, 2000%
or 3000% of the volume occupied by the original unexpanded mass of
expandable material.

[0042] The material or medium may be at least partially coated with an
active polymer having damping characteristics or other heat activated
polymer, (e.g., a formable hot melt adhesive based polymer or an
expandable structural foam, examples of which include olefinic polymers,
vinyl polymers, thermoplastic rubber-containing polymers, epoxies,
urethanes or the like) placed along the mold through the use of baffle
technology; a die-cast application according to teachings that are well
known in the art; pumpable application systems which could include the
use of a baffle and bladder system; and sprayable applications.

[0043] Formation

[0044] The noise reduction member of the present invention may be formed
according to a variety of protocols. Generally, the mass of expandable
material is placed adjacent one or more walls of the carrier member. It
is contemplated that the carrier member may be formed to its desired
shape followed by placement of the mass of expandable material at least
partially within or more substantially entirely within the cavity formed
by the carrier member. In the illustrated embodiment, the carrier member
12 is formed to shape and the mass 14 is automatically,
semi-automatically or manually placed within the cavity 30 of the carrier
member 12. As can be seen, the flanges 60 of the carrier member 12
contact and/or extend into the mass 14 of expandable material for
maintaining the position of the mass 14 relative to the carrier member
12.

[0045] In alternative embodiments, it is contemplated that the carrier
member may formed (e.g., bent or otherwise shaped) about the mass of
expandable material such that the mass of expandable material is
automatically located within the cavity defined by the carrier member. In
such an embodiment, a machine such as a press may be employed to press
fit the carrier member about the mass of expandable material.

[0046] As another alternative, the mass of expandable material and carrier
member are formed and/or shaped substantially simultaneously or at close
proximity in time relative to each other (e.g., within 30 minutes, 2
minutes or even 10 seconds). For example, material of the carrier member
and the expandable material may be co-extruded and then the coextrusion
may be cut to shape the noise reduction member.

[0047] Application

[0048] The noise reduction member may be applied to a variety of locations
upon a variety of structures of a variety of articles of manufacture.
Typically, the attachment of the noise reduction member will be employed
for attaching the noise reduction member to a structure of an article.

[0049] For automotive vehicles, the noise reduction member can be located
within cavities that are at least partially or substantially entirely
formed by automotive vehicle structures such as frame members, body
members, roof rails, closure panels (e.g., doors, hoods, trunk lids, tail
gates, etc.), or others. In one embodiment, the noise reduction member is
particularly suitable for application, acoustic dampening, baffling,
sealing or a combination thereof within or adjacent a pillar (e.g., a
forward or A-pillar, a central or B or C-pillar or a rearward or C or
D-pillar) of an automotive vehicle. For example, the baffle may be
located adjacent or within a cavity formed by the pillar for prohibiting
or inhibiting the passage of material or sound through the cavity.

[0050] Generally, after location of the noise reduction member relative to
a structure, the mass of expandable material is typically activated to
flow, expand, foam, cure, harden, adhere or any combination thereof. If
located within a cavity of a structure, the mass is typically activated
to expand or foam to substantially fill and span a cross-section of the
cavity of the structure for prohibiting or inhibiting the passage of
material or sound through the cavity.

[0051] In FIG. 3, the exemplary member 10 has been placed in a cavity 70
of a structure 72 of an automotive vehicle. The structure 72 illustrated
is a frame structure or pillar of a vehicle but it shall be understood
that the structure may be any of structures discussed herein and other
structures as well.

[0052] For at least temporarily locating the member 10 in the cavity 70,
the fastener 44 of the member 10 has been attached to the structure 72.
In the illustrated embodiment, the flange 46 of the fastener 44 of the
noise reduction member 10 is extended into and through an opening 78
(e.g., a through-hole) in the structure 72 for attaching the member 10 to
the structure. As shown, a cavity 80 is defined between the fastener 44
and the mass 14 of expandable material, the carrier member 12 or both for
receiving an edge 82 of a panel 84 of the structure 72 upon insertion of
the fastener into the opening 78 of the structure 72. Also, as shown, the
cavity 80 includes a widened receiving portion 88 defined by the third
outwardly angled portion 54 of the fastener 44 for assisting in extending
the fastener 44 through the opening 78 and receiving the edge 82. As can
be seen, the member 10 has been located in the cavity 70 such that the
first or top wall 20 is directly adjacent and/or below an opening 90
(e.g., a through-hole) in the structure 72 and/or the second or bottom
wall 22 is directly adjacent and/or above another opening 92 (e.g.,
through-hole) in the structure 72.

[0053] Upon activation of the mass 14 of expandable material, the mass 14
foams and expands within the cavity 70 of the structure 72. As shown in
FIGS. 4 and 5, the mass 10 is expanded to form or expanded a foam
material 96 that adheres to walls of the structure 72 defining the cavity
70 and expands such that the foam material 96 substantially fills and
span a cross-section 98 of the cavity 70 of the structure 72 for
prohibiting or inhibiting the passage of material or sound through the
cavity 70. In this manner, the member 10 forms a noise recuction system
100 in conjunction with the structure 72. Advantageously, the opening or
hole 40 in the side wall 24 allows the foam material 96 to expand and/or
extend through the opening 40 and connect with other portions of the foam
material 96 such that the foam material 96 more substantially entirely
spans the cross-section 98 defined by a plane extending outwardly and
into from the page at the line defining the cross-section 98 to inhibit
or prohibit passage of sound (e.g., noise) and mass or materials through
the cavity.

[0054] As an added advantage, the first or upper wall 20 of the carrier
member 12 and/or the second or lower wall 22 of the carrier member 12
prohibit or at least inhibit the mass 14 of expandable material from
expanding over and partially or substantially entirely covering the
openings 90, 92 of the structure 72 by the foam material 96. As can be
seen, the walls 20, 22 assist the expandable material in forming the foam
material 96 with cavities 110 that provide space about the openings 90,
92. Thus, these openings 90, 92 remain useful for allowing components
such as wiring to extend into and through the openings 90, 92.

[0055] Unless stated otherwise, dimensions and geometries of the various
structures depicted herein are not intended to be restrictive of the
invention, and other dimensions or geometries are possible. Plural
structural components can be provided by a single integrated structure.
Alternatively, a single integrated structure might be divided into
separate plural components. In addition, while a feature of the present
invention may have been described in the context of only one of the
illustrated embodiments, such feature may be combined with one or more
other features of other embodiments, for any given application. It will
also be appreciated from the above that the fabrication of the unique
structures herein and the operation thereof also constitute methods in
accordance with the present invention.

[0056] The preferred embodiment of the present invention has been
disclosed. A person of ordinary skill in the art would realize however,
that certain modifications would come within the teachings of this
invention. Therefore, the following claims should be studied to determine
the true scope and content of the invention.